5s Lean Presentation

5 Steps to a
better workplace
World-Class-Manufacturing.com

World-Class-Manufacturing.com 2
The purpose of 5S is to
promote a safe and efficient
work environment
 5S is a method that uses
five Japanese words which
start with the letter S
What is 5S?
− Is it just another ”cleaning
campaign”?
− No – this is the end of one-
shot cleaning campaigns!

 How do we know if we have working 5S System?
− If we do not have to clean a bit extra before an important visit

 Improved safety
− No items on the floor
− Safety device in their right
places
− Less dust
− Better overview
− Less stress
Reasons to implement 5S

 Improved safety
 Fewer breakdowns
− Less wear from dust or grit in
moving parts
− Fewer errors from electronic
systems due to bad
environment

 Improved safety
 Better work environment
− A clean and well functioning
work place
− Fix the unsafe and cluttered
work stations

 Improved safety
 Less environmental impact
− Leakages such as oil will
easily be spotted
− Using less floor space may
reduce energy consumption

 Improved safety
 Fewer human errors
− No outdated work instructions
− Small but annoying faults are
fixed
− Fewer visual distractions
when working
− It should be easier to do it
right than wrong!

 Improved safety
 May find problems earlier
− When you clean a machine
you inspect at the same time

 Improved safety
 May find problems earlier
 No searching
− Effective tools at the right
place

•11
 Higher moral, motivation
 Practical training in Lean for
leaders and co-workers
 Better impression
 Easier to recruit good people
Indirect gains with 5S
Everyone should be able to work at a
workplace that they can proudly
present to others!

Think break
 What would be the benefits for us if we
implemented 5S?
 What problems do we have today?
 What could be root causes of today’s
problem?

The five steps in 5S
Seiri - Sorting
Seiton - Organizing
Seiso - Cleaning
Step 5 – Discipline
Seiketsu – Routines
Step 1
Step 2
Step 3
Step 4
Step 5

Step 1 – Sorting
 Sorting has two main
purposes
1. Remove unnecessary
objects
2. Reduce waste
 Sorting is a team activity
that will be carried out
by the production and
maintenance personnel
together
Step 1 – Sorting

 Go through the whole plant
− Machine and control positions
− Work areas
− Storage and common areas
 Look for
− Materials
− Behind or under machines
− Rejects
− ”Forgotten” material
Step 1 – Sorting
Remove unnecessary
objects

Go through the whole plant
−Machine / control positions
−Work area
−Storage and common areas
Look for
−Materials
−Tools
Not in use
Worn out or broken
”Custom-made” tools – made out
of tape or steel wire
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
Broken
Surplus inventory
Spare parts for machines no
longer in use
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
−Out-of-date Documentation
Instructions
Binders
Manuals
Common folders in the computer
system
Duplicates: digital and/or paper?
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
−Out-of-date documentation
−Computerized systems
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
−Out-of-date Documentation
−Bulletin board
−Other stuff
Outdated process equipment
Et. cetera
Step 1 – Sorting
Remove unnecessary
objects

 Look at each object
 Ask yourself: Do we need it at
all?
− If not – Discard it, or sell it
 Ask yourself: Will we need it
soon?
− If not – Put it into proper
storage (e.g. ”spare parts”)
Step 1 – Sorting
Remove unnecessary
objects

Step 1 Seiri - Sort
Each item to be discarded or
corrected is marked with a red
tag
The red tag gives everyone the
opportunity to speak up on the
proposed action.
A quarantine area can be created
for the object you are unsure of.
A red tag should never be up for
more than 30 days.
Date: Tagged by:
Item description:
Reason tagged:
Tag No:
Remove unnecessary
objects

Waste elimination
23
Step 1 – Sorting
 The second purpose of
sorting is to reduce waste
and generate ideas for
improvements
 We will try to identify
everything that is hindering
us from working safely and
efficiently

 Identify:
 Work instructions
− Do we have them?
− Are they up-to-date?
− Are they in use? If not – why not?
Step 1 – Sorting
Waste elimination

 Identify :
Work instructions
Safety
−What measures should we take to
eliminate the risk of fires and accidents?
Remove clutter
Improve unsafe electrical installations
Replace broken safety devices
Repair broken steps
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
−What measures do we need to
minimize or prevent damage to the
environment?
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Tools and equipment
−Anything missing?
−Anything not working properly?
−Anything in need of improvement?
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Inconvenient work positions
−Seating and work surfaces at
the right heights?
−...and adjustable for different
shift workers?
−Awkward angles for moving
materials?
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Deferred maintenance
−temporary repairs (like tape and steel wire)
−obvious technical errors (like strange noises
or smells, leakage, dangling parts)
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Deferred maintenance
Improvement Proposals
−review prior suggestions that were never implemented
measures aimed at improving quality, operating purposes,
procedures, controls, etc.
Step 1 – Sorting
Waste elimination

Step 1 – Sorting
All identified waste items are
marked with an red tag
Date: Tagged by:
Item description:
Reason tagged:
Tag No:
Waste elimination

Step 1 – Sorting
Machine tagged with errors and
improvement suggestions

Date: Tagged by:
Item description:
Reason tagged:
Tag No:
Step 1 – Sorting
Every tag refers to a 5S Sort list

Action plans after
5S sorting

Step 2 – Organizing
Steg 1
Steg 2
Step 1 – Sorting
Step 2 – Organizing The purpose is that
everything that we
regularly use should have
a convenient placement
− Tools should be kept at
the point of use
− No bending to pick up or
move materials
− Alter flow paths to
improve efficiency

A good
example

This presentation is based on the
book ”Succeeding with 5S” by
Oskar Olofsson
Download the full presentation at
http://world-class-
manufacturing.com
37

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